Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best...

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Transcript of Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best...

Page 1: Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best value, most cost effective solution designed for heavy duty diesel applications with
Page 2: Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best value, most cost effective solution designed for heavy duty diesel applications with

Unifrax is a leading producer of high performance specialtyproducts for worldwide emission control, industrial thermal

management and fire protection markets.Our purpose, mission and values are basedon our commitment to produce high qualityspecialty products that help our worldwidecustomers save energy, reduce pollution and improve fire safety. Unifrax was formerlypart of The Carborundum Company, a well-known manufacturer of abrasive and

refractory products founded in 1891. In 1942, one of our ownresearch scientists, J.C. “Charlie” McMullen, invented ceramicfiber which we later trademarked under the Fiberfrax® name.

Today, our Fiberfrax ceramic fiber product line, revolutionaryInsulfrax®, and Isofrax® AES products, Saffil® PCW fibers,glass fibers and other high performance specialty productsare available in more than 50 product forms. Our broad productoffering, outstanding application engineering expertise, andcustomer service support provide innovative thermal man-agement solutions and exceptional value to our worldwidecustomers in the ferrous and non-ferrous metals, industrial ceramics, petroleum products, power generation, ceramic,glass, automotive, fire protection, aerospace, appliance andother industries.

Unifrax worldwide manufacturing and sales facilities are located in the United States, Europe, China, Russia, Japan,India, Korea, South Africa, South America and the MiddleEast, offering our worldwide customers the high quality products, service and support that have been the Unifraxstandard for more than 70 years.

J.C. “Charlie” McMullen,inventor of ceramic fiber.

Unifrax Corporate Headquarters, Tonawanda, New York USA.

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Unifrax ceramic fiber products havebeen used in more emission controldevices than any other material.

Our emission control products help our customers reduce pollutionand contribute to improving the environment.

Unifrax invented ceramic fiber, the base material in all supportmats and Unifrax products that have been used in over two billion emission control devices. Unifrax products were usedin the first catalytic converter produced for General Motorsin 1974 and for the first diesel emission control devices for Volvo in 1988.

Unifrax is uniquely positioned to serve the global emissioncontrol customer base:■ We offer the widest range of products for the automotive

industry.■ We manufacture all our products with the fibers we make.■ We own and control our fiber and mat production facilities,

converting operations and distribution.■ Our presence on six continents and in 17 countries

gives us the broad global footprint needed to serve our customers worldwide.

Our mission is to become the preferred worldwide supplierfor catalytic converter support mats. We intend to accom-plish this by providing our customers with the best value and helping them contribute to improving the environment.Our strong focus on product development, manufacturingefficiencies and sophisticated quality control programs positions Unifrax to be your preferred resource for innovativesolutions for emission control applications in worldwidemarkets.

Page 4: Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best value, most cost effective solution designed for heavy duty diesel applications with

Unifrax is a vertically integrated company offering a completeproduct portfolio of catalytic support mat and thermal management products for emission control applicationsworldwide. With more than 70 years of experience in fibertechnology, Unifrax is the chosen provider for many high profile automobile and commercial vehicle manufacturers offering time and cost savings in the development process,as well as exceptional quality control and high levels of customer satisfaction.

The integration of Saffil Automotive into the Unifrax emissioncontrol business, the establishment of ITM Unifrax-JV inJapan, as well as the acquisition of a number of additionalmarket-related companies in the 2010’s has strengthenedand expanded Unifrax capabilities in the worldwide emissioncontrol market. Our capabilities include:

Research & Development. We develop our own high performance fiber and emission control products.

Manufacturing, Converting & Distribution. We own andcontrol our fiber and mat production facilities, converting operations and distribution.

Technical Service. We maintain technical excellence centersaround the world.

After-treatment support mat systems.

Unifrax owns and controls its own fiber production facilities and converting operations.

Thermal management products.

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Three Distinct & Proven Fiber Chemistries

Polycrystalline Wool (PCW)Highly resilient man-made fibers.

Refractory Ceramic Fiber (RCF)Unmatched experience in RCF technology.

Alkaline Earth Silicate (AES)Low bio-persistence fibers, not classified under EU regulations.

“Green” Solutions for Emission Control

Unifrax is a leading producer of low bio-persistence

fibers, also known as “green” or unclassified, high

temperature AES fibers. Unifrax developed and

patented its high resiliency green fiber Isofrax®

products for use in support mats in 1996. Our

AES fiber support mat and other emission control

thermal management products are available with

and without vermiculite to meet our customers’

application requirements.

Isomat ®AV5 green support mats.

Product Forms

NeedledMechanically bonded, organics-free,fiber-only products.

Non-IntumescentFiber-only products.

IntumescentProducts containing vermiculite.

PCW

RCF AES

Needled

NonIntumescent Intumescent

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Unifrax emission control products are made to meet the demands of stringent regulations and difficult operating conditions. We offer a wide variety of support mats for bothunderfloor and close coupled converters in passenger carsand light duty trucks. All products are REACH compliant andare available with optional flexible edge protection treatment.

PC-Max® Support MatsOur highest performing support mat, PC-Max® 2000i is abinder-free, needled, polycrystalline support mat. PC-Max2000i is manufactured and converted using our unique worldwide supply chain, providing our customers with reduced risk of supply disruption. PC-Max fibers are non-classifiable under GHS.

Ecoflex® Support MatsOur family of Ecoflex® support mats are a cost effective alternative to needled, polycrystalline mats for demanding applications. Ecoflex mats using highly resilient Saffil® and M-Fil® fibers which are non-classifiable under GHS include:

Ecoflex 200FLEcoflex 400

CC-Max® and XPE® Support MatsOur CC-Max® and XPE® support mats are manufactured using refractory ceramic fiber (RCF) and offer the best value for most common applications including under floor and close coupled.

CC-Max 4 HPCC-Max 5XPE-AV2i

PC-Max 2000i support mats for “green” applications.

BMW 1-Series

Chrysler Dodge Ram 2500

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Heavy duty vehicles pose challenging design requirements for after-treatment devices. Unifrax offers a range of support mat products to meet a variety of temperature, gap and loading requirements.

Ecoflex® Support MatsEcoflex® 400 support mats are available as a single layer solution in a wide range of basis weights for quick and easy installation invarious gap applications. The highly resilient Saffil and M-Fil fibersoffer an ideal solution to high gap expansions commonly experienced in heavy duty diesel after-treatment devices.

CC-Max® Support MatsCC-Max® 5 support mats offer a cost effective alternative to theEcoflex family of support mats. This product’s unique refractoryceramic fiber formulation provides a support mat with a holdingforce sufficient for keeping heavy DPF, SCR and DOC intact asthe vehicle experiences high vibration and regeneration cycles.

XPE-MP® Support MatsXPE-MP® provides the best value, most cost effective solutiondesigned for heavy duty diesel applications with proven performance on EPA-2007, EPA-2010 and off road systems.

XPE-MP support mats provide high value,cost effective solutions for heavy dutydiesel applications.

Mercedes Actros

Scania Streamline

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Isomat AV5 support mats with edge protection treatment.

Isomat® “Green” Support Mats The Isomat® family of support mats offers the option of using low bio-persistence fibers without compromising product performance. Isomat support mats are manufactured usingpatented, highly resilient alkaline earth silicate (AES) fibers and areavailable with and without vermiculite to meet application needs.

Isomat® AV5Isomat AV5, our premium performance AES fiber mat has beenused in approximately 20 million devices in light duty and heavyduty vehicles meeting Euro IV, Euro V and Euro VI regulations.

Isomax® 1Isomax® 1, our fiber-only support mat made with AES fibers is ideally suited for both light and heavy duty applications where use of low bio-persistence fibers is required.

MAN TGA

Volkswagen GolfPhoto courtesy of Volkswagen Aktiengesellshaft

Page 9: Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best value, most cost effective solution designed for heavy duty diesel applications with

For more than 40 years, Unifrax has provided thermal management solutions to the automotive industry. Our products are used to meet the stringent quality standards ofthe automotive industry to protect heat sensitive components,extend equipment life and ensure passenger comfort andsafety. Typical passenger car applications include laminateheat shield insulation, and cone insulation for after-treatmentdevices. Unifrax has also developed insulation solutions forboth on road and off road heavy duty, commercial vehicleshelping customers to meet demanding skin temperature requirements.

Isomax® 110Isomax® 110 is a needled, shot free, AES fiber blanket. Its low thermal conductivity and high temperature use limitmake it ideally suited for insulating SCR, DPF and DOC inheavy duty, commercial vehicles with high regeneration temperatures.

VC-Max™ 1 InsulationVC-Max™ insulation is a molded three-dimensional, high performance, engineering insulation material composed of Saffil polycrystalline, high alumina fibers designed to withstandhigh vibration and temperature exposure.

QSP® InsulationQSP® insulation is a two-dimensional sheet form, high performance material made of refractory ceramic fibers typically used in all types of after-treatment devices. QSP insulation combines excellent thermal stability at high temperatures, high insulation properties, low erosion profileand low shot content in a lightweight, flexible product that can be cut in all shapes and sizes.

Isomax 110 is a needled insulation blanket ideal for heavy duty applications.

VC-Max 1 insulation is designed to withstand high vibration and temperature exposure.

Unifrax has developed insulation solutions for both on road and off road heavy duty vehicles.

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To meet high quality standards with maximum product performance while maintaining cost-effectiveness, Unifraxuses a cross-functional team approach in conjunction with a Staged Gate Process for new product development.

Focusing on customer application needs, our teams of ceramists and engineers have developed a variety of customized laboratory equipment, as well as proprietary test protocols and hot shake testing, to aid in the under-standing of key performance criteria. This understanding has led to a successful portfolio of automotive support mat products including XPE and Isomat intumescent mat products, as well as CC-Max, Isomax, Ecoflex and PC-Max non-intumescent mats.

The Unifrax team will work closely with your product development and quality engineers and your manufacturingor commercial staff to identify key performance criteria. Together, we can develop an engineered support mat system with the specific properties required to meet therigorous performance targets of your after-treatment system.

Our experienced application engineersdevelop emission control productsto detailed customer specifications.

A research scientist performs a chemical analysis using X-ray fluorescence.

A technician prepares to take a fiber surfacemeasurement using nitrogen adsorption.

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Unifrax performs rigorous and comprehensive quality controltesting necessary for maintaining the quality levels that our customers demand. We are the recipient of a number of prestigious supplier awards and are a preferred supplierthroughout the emission control industry.

Unifrax maintains an extensive database network incorporatingall major management and operating functions, which allowsus to operate a nearly paperless system. Employees are able to access, in real time, customer specifications, part drawings,control plans and customer specific requirements to ensureconformance to our customer’s needs. Our quality certificationsinclude: ISO 9001:2008; ISO/TS-16949:2009.

Accelerated aging tests are usedto predict performance in the field.

Our state-of-the-art pilot scale equipmentallows us to study various formulationsquickly and efficiently.

Comprehensive quality control testingmaintains the demanding quality levelsrequired by our customers.

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Unifrax has a diverse set of manufacturing technologiesthat can be used to develop desired properties in the product. Closed loop, computer controlled and wet laidpapermaking processes can be used to deliver productswith best-in-class weight and thickness control. Unifrax utilizes its more than 70 years of experience in needlingtechnologies to bring top performing support mats to ourworldwide customers. Our patented water jet process iscapable of cutting complex shapes with extreme precisionwhile rendering them dust free.

Our closed loop, computerized wetprocess can produce a wide basis weightrange of single-layer paper with exceptional uniformity and performance.

Unifrax uses patented waterjettechnology for precision cuttingand edge coating of products.

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Unifrax Worldwide Manufacturing Locations

Unifrax maintains 26 manufacturing locations in 12 countries.

Brazil

China

Czech Republic

France

Germany

India

Japan

Kingdom of Bahrain

Russia

South Africa

United Kingdom

United States

Online gauging provides processfeedback and insures productconsistency and quality.

Unifrax maintains state-of-the-art converting facilitiesaround the world providing reliable delivery of high quality,just-in-time products to the customer’s site. All ourprocesses, including manufacturing and converting arelinked with a redundant bar coding system providing fulltraceability and supply chain integration.

State-of-the-art lot and location control and bar coding systemsinsure efficient delivery of finished products.

Page 14: Our purpose, mission and values are based · XPE-MP® Support Mats XPE-MP® provides the best value, most cost effective solution designed for heavy duty diesel applications with

Mounting Mat Quick Reference

Other basis weights are available upon request. Please consult with a Sales or Applications Engineer for details.Data is for mat products only, does not include any tapebacking or encapsulation effect.*The DE (German) classification is not for fibers, but "workplace dust" following TRGS 905.

Insulation Quick Reference

*All data shown are nominal values and do not represent product specification.**Currently under development***The DE (German) classification is not for fibers, but "workplace dust" following TRGS 905.

1 Mullite Polycrystalline Wool (PCW)2 High-Alumina Polycrystalline Wool (PCW)3 Calcium-Magnesium Silicate (AES)4 Magnesium Silicate (AES)

Ecoflex 400 support mats

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Unifrax emission control products are backed by more than 70 years of innovative thermal management experience.

1942Refractory ceramic fiber is invented

by J.C. “Charlie” MMullen, a research scientist at

The Carborundum Company in Niagara Falls, New York USA.

1993Introduction of Insulfrax specialty

glass fiber products, a breakthroughin insulating materials offering

enhanced solubility characteristics. 1996The Carborundum Company NorthAmerican Fibers Division becomes astand alone company doing businessas Unifrax Corporation.

1998-1999Introduction of Isofrax ThermalInsulation, a revolutionary fiber

designed to meet European regulatory requirements, and

the recipient of the prestigious R&D 100 Award in 1999.

Early 2000sFiberfrax products for the automotivemarket shift to a focus on emissioncontrol to meet the needs of changingrequirements in the automotive industry.

2007-2008In 2007, Unifrax acquires Keraunion, a ceramic

fiber producer in Dubi, Czech Republic whichbecomes Unifrax Czech, followed by the opening of a new ceramic fiber facility in

Suzhou, China in 2008.2011Unifrax acquires a variety of market-related companies including Refractory Specialties Incorporated, Specialty Ceramics, Inc., VacuForm, Bondlye and Saffil.

UNIFRAX

2013Unifrax enters into a joint venture

agreement forming ITM Unifrax in Japan.

1974The first submerged electrodefurnace (SEF) for the production ofceramic fiber is built and the FiberfraxDurablanket® line is introduced.

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North AmericaUnifrax I LLC Tonawanda, NY USATelephone: +1-716-768-6500

Unifrax I LLCChelsea, MI USATelephone: +1-734-475-0700

South AmericaUnifrax Brasil LtdaVinhedo, SP BrazilTelephone: +55-19-3322-8000

EuropeUnifrax Emission Control EuropeGreenfield, Holywell, Flintshire, UKTelephone: +44 1352 712331

Unifrax GmbHDüsseldorf, GermanyTelephone: +49 211 52391 255

AfricaUnifrax Emission Control South Africa (Pty) Ltd.Port Elizabeth, South AfricaTelephone: +27 41 463 1240

AsiaUnifrax India Ltd.Pune, Maharashtra, IndiaTelephone: +91-20-4075777

Unifrax (Shanghai) Ltd.Shanghai, ChinaTelephone: +86 21 50464566

Unifrax APH Ltd.Seoul, KoreaTelephone: +82 2 552 9766

Unifrax Japan Ltd.Mihama, Chiba, JapanTelephone: +81 43-297-3924

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Unifrax I LLC Corporate Headquarters600 Riverwalk Parkway, Suite 120Tonawanda, NY 14150 USATelephone: 716-768-6500Email: [email protected]

Form C-3057© 2015 Unifrax I LLCPrinted in USAAll rights reserved

The information, recommendations and opinions set forth herein are offered solely for your consideration, inquiry and verification and are not in part or total, to be construed as constituting a warranty or representation for which we assume legal responsibility. Nothing contained herein is to be interpreted as authorization to practice a patented invention without a license.

All trademarks and registered trademarks used herein are the sole property of Unifrax I LLC.w w w. u n i f r a x . c o m